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FUELSYSTEM 22-1

GROUP22

FUELSYSTEM
CONTENTS
Diagnosis. .. 22-6
FuelGaugeDiagnosis 22-7
Fuelfnjector Inspection. ........ 22-12
C h e c kO p e r a t i o n . .....,... 22-12
FuelLeakage Test.. .. . .. 22-12
fniectorResistance .. ... .. .. 22-13
V o l u mTee s t ....... 22-12
FuelLineHandling. .. 22-8
Primingthe FuelSystem 22-B
FuelPumpInspection. 22-9
HoldPressure ..... 22-10
F u eP l u m pM a x i m u P mr e s s u r e ........ 22-10
FuelPumpOperation. 22-9
FuefPumpBelayInspection .... 22-10
CheckOperation. .. 22-10
Continuity Inspection ........ 22-'l'1
GeneralDiagnosis .. ... .. 22-6
Pressure Regulator Inspection .. ... ..... 22-11
F u eL l i n eP r e s s u r e ......... 22-11
HofdPressure ..... 22-11
ReleasingFuelSystemPressure 22-A
SystemChecks 22-8
FuelLinePressureInspection 22-9
Fuel PressureHoldInspection 22-8
GeneralDescription ... ... 22-2
Air FuelInduction System. 22-2
Electronic FuelPumpAssembly ...... 22-2
FuelFilters 22-2
Fuel Pipesand Hoses. 22-3
Fuel PressureRegulatorValve .. 22-3
FuelSenderAssembly .... 22-3
FuelTank. .. 22-3
FuelTankPressure Sensor.. .. 22-3
On-Vehicfe Service.. ... 22-13
A i rC l e a n eErl e m e n. t ......... 22-30
AirCleaner Assembly andBracket. ....... 22-30
A i rF u n n e l ......... 22-3'l
Air IntakeHose.. . . .. 22-32
A i rf n t a k De uct.... ... 22-32
Checkand CutValve 22-25
Dynamicchamber .... 22-35
FreshAirDuct..... . .. 22-32
FuelDistributor. ...... 22-35
FuelFilter .. 22-29
Fuellnjectors ..... . .. 22-36
Fuel Lines 22-26
FuefPump. 22-19
FuelPumpAssembly ... .. .. . .. 22-15
FuelPumpAssembly Filter ..... 22-17
22-2 FUEL SYSTEM

z1-tJ
FuelTankSenderAssembly 22-21
FuelTankPr€ssureSensor. . 22-23
ldleAir ControlValve.. . . z1-,7,1
InjectorInsulators 22-38
I n l eP
t i p eA s s e m b l y . . . . . . . 22-r'7
MassAir FlowSensor. a1-,t I
PCVValveand Ventilation Hose.. . . 22-31
22-U
PressureRegulator. 22-30
Quickconnector. 22-43
ResonanceChamber
VaporSeparalorAssembly. 22-28
ThrottleBody 22-33
ThrottlePositionSensor.. 22-34
Specitications 22-44
FastenerTighteningSpecifications. 22-44
GeneralSpecifications
.... 22-44

GENERALDESCRIPTION The ECM-controlled idleair controlvalvesupplies


elitraair to maintainidlespeed.E)draair is suDolied
to
The fuel systemfor the Sportageconsistsof the increaseidlespeedwhentheengineis cold.ldle
tollowingcomponents: speedis increasedwhenthe air conditioning
. Electronicfuel pumpassembly compressoris engagedor when mechanicalload
. Fuelfilters(2) affectsidle speed.
. Fuelpipes(lines)and hoses Crankcasegasesareventedto the intakemanifoldby
the positivecrankcaseventilationPVC valve.The PCV
. Fuelsenderassembly valveis operatedby intakemanifoldvacuum.At idle
. Fueltank the PCV valveopensslightlyand allowssome
crankcasegasesintothe combustionchamber. As rpm
. Fuelrail increase,the PCVvalveopeningincreasesallowinga
. Fuelpressureregulator largervolumeof gasesintothe intakemanifold.
. Fuelinjectors(4) ELECTRONIC
FUELPUMP
. Fuelpumprelay ASSEMBLY
. Pulsationdamper The electronictuelpumpassemblysuppliesfiltered,
pressurizedfuelto eachfuel injectorthroughthe fuel
AIR FUELINDUCTION
SYSTEM rail.The Juelpumpassemblyis mountedin the fuel
The air fuel inductionsystemcarries,filters,measures, tankto reducepumpoperatingnoise.lt is mounted
and controlsthe Jlowof air intothe throttlebodv.Fuel with and connectedto the fuel sendingassembly. Both
is meteredand mixedwiththe air in the intake assembliesare removedfromand installedintothe
manifold.Air volumeintothe engineis regulatedby the fueltank as a singleunit.
accelerator cable-controlledthrottleDlatesmountedin The fuel pumpis an electricpumpcontrolledby the
the throttlebody. enginecontrolmodule(ECM)throughthe tuelpump
Fuelis deliveredto the solenoidoperatediniectors relay.Whenthe ECMcommandsthe fuel pumprelay
throughthe luel rail.Fuelpressureis controlledby a to operate,the motorrotatesan imDellerwithinthe
variablepressureregulatorwhichvariesfuel pressure pumpassembly.Thiscausesfuel withinthe fueltank
dependingon the absolutemanitoldpressureactingon to be drawnintothe fuel inletport. Fuelis pumpedout
the regulatorat the time. to the throttlebodyandfuel rail and iniectorsunder
pressurethroughthefuelfeedpipe and hose.The fuel
An electricalpulseactivatesa solenoidwithinthe fuel pressureis retainedwhenthe fuel pumpis not running
injectorbody.The duraiionof the pulseis determined
by the ECM.The ECMvariesthe pulsedurationbased by meansof a controlvalvelocatedwithinthe pump.
uponthe amountof air passingthroughthe massair ExcessJuelis returnedto the fuel tank bv meansof a
flow sensorand the enginespeedwhichis determined fuel retumpipeand hose.
by the crankshaftsensor. FUELFILTERS
A throttlepositionsensorattachedto the throttleplate A steelin-linefuel,ilteris usedin the fuelfeedpipe
shaftsignalsthe ECMof the throttlepositionand the aheadof the fuel iniector. The filter housingis
rateof the throttlemovement.Thesesignalsinfluence constructedto withstandtemperaturechangesand
the injectorpulseduration. exposure.lt hasa papertilterelementwhichtraps
FUELSYSTEM 22-3
particlesthat coulddamagethe fuel iniectionsystem.A FUELTANK
screenfilter in the fuel pumpassemblyfiltersout
particlesin the fueltankJurtherprotectingthe system. The fueltank is usedto storefuel for thevehicle.lt has
a 15.8gallon(60 lite0 fuel capacity.Thetankis formed
FUELPIPESAND HOSES fromsteeland is locateddirectlyin frontof the rear
Fuelfeed and retumpipes(lines)and tubescarryiuel wheelsin backof and belowthe rearseat.
tromthe fuel tankto the tuel railand backto the fuel The tueltankis held in placewithtivebolts.The tank is
tank.Thesepipesandtubesare attachedto the protectedby a gravelshieldto whichit is mounted.The
underbodyof the vehicleand mustbe inspectedfor shapeot the tankallowsfor a conslantsupplyof fuel
kinksor dentswhichmayrestrictfuelflow. aroundthe fuel pumpscreenfilterdunnglowfuel
Fuelvaporpipesand hosescarryfuel vaporsfromthe conditionsandduringaggressivevehiclemaneuvers.
fuel tank to the evaporative The fuel inletporton the tank is equippedwithan inlet
emissionscanisterlocated valve.The tueltank inletvalveoreventsfuelfrom
in the enginecompartment. The fuelvaporsare stored
in the canisterwhenthe engineis not running.When spewingintothe fuel filler neckduringabnormalvehicle
the engineis runningat normaloperatingtemperature, drivingconditions.
and lhe acceleratorpedalis depressed,the engine To maintainproperfuel systempressure,it is
controlmodule(ECM)willcommandthe evaoorative imperativethatlhe fuel tiller cap be functioning
properly
emissionsolenoid purgevalveto openand allowthe and that it "Clicks"whenscrewedintothefillerneckof
storedfuel vaporsto be purgedintothe intake the gastank.
manifoldand be absorbedintothe combustion The tueltank,alongwith its pipesandhoses,shouldbe
orocess. checkedtor roaddamagewhichcouldresultin leakage.
FUELSENDER
ASSEMBLY Alsoinspectthe fuel {illercap for a correctsealand
indications of physicaldamage.
The fuel sendingsystemconsistsof a float,floatarm,
and a variableresistor.Fuellevelis measuredby the FUELPRESSURE
REGULATOR
positionof the floatin the fueltank,and is indicatedby
a gaugein the instrument panelclusterassembly.
VALVE
Whenthe luel levelchanges, thefloatposition The pressureregulatorregulatesthe iniectionpressure
changes.The changein floatpositionincreasesor so that it is maintainedat a pressuregreaterthan
decreasesthe resistance of the variableresistor.The 290 kpa(40.5psi)than the pressurein the intake
changein resistancecausesthe positionof the fuel manifold.
gaugereadoutto change. The pressureregulatorconsislot a diaphragm, a spring
and a fuel returnpipe.
The calibratedspringpressureagainstthe diaphragm
and closeolf returnpipe.
The systempressurereflectsthe amountol fuel
pressurerequiredto open the returnpipe.
The fueltankis filledthroughthe fuelfillerinletport
coveredby a protectivecontrol-opened panelon the
rightsideol the vehicle.
FUELTANKPRESSURE
SENSOR
The fueltankpressuresensorlocatedat the fuellank is
an integralpartof the monitoringsystem.The fueltank
pressuresensorcheckspurgevalveoperationand leak
detectionin the evaporativeemissionssystemby
monitoringpressureand vacuumlevelsin the iuel tank
duringand betweenpurgeoperatingcycles.
22-4 FUELSYSTEM

12
&,_.-,,
G-

(il;EP
\-

20

1 Checkand Cut Valve 11 FillerLid


2 VaporSeparator '12 Filler
Lid Opener
3 ReturnLine 13 FillerInlet Neck
4 FeedLine 14 Fuel Pump
5 FuelFiller(HighPressureSide) 15 Fuel Pump Filter (Screen)
6 FuelInjector(4) 16 Fuel Sender Assembly
7 FuelPressureRegulator 17 Fuel Tank Pressure Sensor
I FuelPumpAssembly 18 RolloverValve
I PulsationDamper 19 Check Valve
10 FuelTank 20 Canister Close Valve
FUELSYSTEM 22-5

1 . MassAir Flow(MAF)Sensor
Air Cleaner
.t. Resonance Chamber
4. ThrottleBody(lncludesThrottlePositionSensor)
Plenum
b . ldleAir Control
Valve
22.6 FUELSVSTEM

DIAGNOSIS
GENERAL
DIAGNOSIS
Problem PossibleCause Aclion
Engineclanks but will Fuelpressureproblem Replacefuelpressureregulator
not slan Replaceleakinginjeclor
ReplaceinjectorO-ring
Hald lo start (cold ldleair controlvalvenotworking Replace
en9ine) Detectivethrotlleposilionsensor Replacethrottlebody
Fuelpressuretoo low Replaceregulator
Coolanttempsensoropencircuitor out ot range Repairhamess
Beplacesensor
Rough idle (cold Throttlevalvesimproperly
adjusted Adjustthrottle
engine) Fuelinjectorflow Beplaceinjector
Throttleplalestuckopen Cleanand adjustthrottleplate
Adjustthrottlecable
Throttlef,osilion switchsluckopen Replace
ldleair controlvalveinoperative Replace
Air iniakeductdisconnected between Reconnect air duct
MAFand th.ottlebody
Leakinginjector Beplace
LeakinginjectorO-ringseals Replace
Slalling or hesitalion Throttlepositionsensorfailed ReplaceTP sensor
(hot or cold engine) EGFIvalvemalfunction Replace
Hard slart (hot engine) Inconectluel pressure Checkpressu.eregulalortuelpump
Stalls on quick stops or Mais air flowsensoropencircuitout ol range ReplaceMAFsensor
deceleration circuii(seeETM)
Checkelectrical
Pool pertormance/loss Cloggedinjectors Checkinjeclortlow rate
ot power Airfiherclogged Replace
FUELSYSTEM 22.7

FUELGAUGEDIAGNOSIS
Ploblem Possible Cause Action
Fuelgaugeshows Looseor dirtywiringconneclions
or shortto groundwiring Checkwiring,connecto.sandsenderassembly.
empty at all levelsol lill Repair,cleanor tightenas needed.
Leakingsenderfloat Beplacesender
Missingsendertloat Installfloat.Makesurefloatis secured
on sender
arm.
Shortcircuitin senderassembly Testtor conect resistancevaluesandreplaceas
needed.
Senderassembly
arm movement
obslructed Inspectfueltankand senderfor cause.Replace
faultycomponent.
Fuelgaugewill not Wrongsenderinstalled Checkpartnumber.It inconecl,installcorrectpart.
readtull when tank is Senderarmmovement (floatrodbent)
obstructed Inspectlueliank and senderfor cause.Replace
full taultycomponent.
Leakinglloat lnstallnewsender
Senderor gaugecalibration Testlor conect resisianceva[re andreplace
component as needed.
Fueltanknotfillingto ratedcapacity Checktueltankfill ventfor kinksor obstructions.
Correctas requiredandlill tankto verilyproper
capacity.
Fuelgaugeshows tull Looseor dirtywiringconnections
or opencircuitin wiring Checkwiring,connections andsenderlermtnaF.
ai all levelsol fill Repairor cleanit required.
Opencircuitin sendingunit Testlor correctresistancevaluesand replaceit
requrred.
Senderarmmovement
obslructed Inspectfueltankand sendertor cause.Gently
bendfloat arm awaylrom obstructionor
replacecomponent.
Inaccude indications Fuel lank damage Fuel sender mounting angle may have changedor
continuebut all fuel the sender unit may bs damaged.
syslem components
are runningproperly
22.8 FUEL SYSTEM

1 . Connectthe data linkconnectorterminalsFUEL


PUMPand B+ witha jumperwire.
RELEASING
FUELSYSTEM
Turnthe ignitionswitchon for no longerthan1O
PRESSURE secondsto pressurizethe systemand checkfor
A mnuHc fuel leaks.Ohe jumperwire gets hot if it is leftIn tor
THEFUELSYSTEMREMAINSUNDER longerthan10 seconds.)
PRESSURE WHENTHEENGINEIS NOT 3. Tumthe ignitionswitchoff and takethejumperwire
RUNNING, RELEASEFUELSYSTEMPRESSURE off the datalink connector.
BEFOREDISCONNECTING ANY FUELLINETO
REDUCETHECHANCEOF PERSONAL INJURY
OR FIREDAMAGETO VEHICLECOMPONENTS,
1. Startthe engine.
2. Disconnectthe fuel pumpconnectorlocatedbehind
lhe vehiclerearseat,floorlevet.
3. Letthe enginestall,thenturn off the ignitionswitch.
4. Connectthe fuel pumpconnector.

l(lar 63-22.{'a\s

SYSTEMCHECKS
FuelPressureHold Inspection
1. Disconnect the negativebatteryterminal.
A WARNING
1 FuelPumpAssembly THEFUELSYSTEMREMAINSUNDER
2 FuelPumpAssembly
ElectricalConneclor PRESSURE WHENTHE ENGINEIS NOT
RUNNING. BELEASEFUELSYSTEMPRESSURE
BEFOREDISCONNECTING ANY FUELLINETO
REDUCETHECHANCEOF PERSONAL INJURY
OR FIREDAMAGETO VEHICLECOMPONENTS.
FUELLINEHANDLING Releasefuelsystempressure. Referto "Releasing
A wanrurlc FuelSystemPressure"in this section.
FUELIS EXPLOSIVE. WHENWORKINGON Installa fuel pressuregaugeto the pressureport
FUELSYSTEMPARTS.MAKESURETO locatedon ihe frontof the fuel rail.
SUPPLYADEOUATEVENTILATION TO THE
WORKAREA.DO NOTSMOKE,AND KEEP
SPARKSAND OPENFLAMESAWAY.
1. Whendisconnecting fuelhoses,usea shoptowel
to absorbfuel,protectingequipmentand personnel.
2. Stopfuel leakageby installing
hoseclampswhere
thefuelfilterandthe mainfuelhoseconnectto the
luel pressuregauge.

Primingthe FuelSystem
Afterfuel pressurehas beenreleasedfor repairsor
inspection,the systemmustbe primedto avoidtoo
muchcrankingto restartthe engine.Followthe steps
below.
FUELSYSTEM 22-9

4. Connectthe negativebatteryterminal. 5. Connectthe datalinkconnector terminals


FUEL
5. Connectthe datalinkconnector terminalsFUEL PUMPand B+witha jumperwire.
PUMPand B+ witha jumperwire. 6. Turnthe ignitionswitchon for 10 seconds.
6. Turnthe ignitionswitchon for 10 secondsto runthe 7. Checkfuellineoressure.
fuelpump. Fuel line pressure:42 psi (292.5kPa)
7. Turnthe ignitionswitchotf and removethe jumper
wtre. 8. Turnthe ignitionswitchoff and removethe jumper
wire.
8. Checkfuel pressureafter5 minutes. 9. lf notas noted,do thefollowinginspections:
Fuelpressure:Morethan 21psi(150kPa) . Fuelpumpmaximum pressure.
9. lf notas noted,do the followinginspections: . Fuellineclogging and restriction.
. Fuelpumpholdpressure. . Fuelfiltercloggingand restriction.
. Pressureregulatorholdpressure. . Pressureregulatorholdpressure.
. Injectorfuel leakage.

FUELPUMPINSPECTION
A uRl,tl1c
THE FUELSYSTEMREMA'NSUNDER
PRESSURE WHENTHEENGINEIS NOT
RUNNING.RELEASEFUELSYSTEMPRESSURE
BEFOREDISCONNECTINGANYFUELLINETO
REDUCETHECHANCEOF PERSONAL INJURY
OR FIREDAMAGETO VEHICLECOMPONENTS.
FuelPumpOperation
1. Connectthe datalinkconnectorterminalsFUEL
'rs
PUMPand B+witha iumoerwire.
Ktar6:122-t

FuelLine PressureInspection
1. Disconnectthe negativebatterycable.
2. Releasefuel systempressure.Referto "Releasing
FuelSystemPressure"in this section. 2. Removethe fuelfillercap.
3. lnstalla fuel pressuregaugeto the pressureport 3. Turnthe ignition switchON.
locatedon the frontof the fuel rail. 4. Determine if thefuelpumpis runningby listening
4. Connectthe negativebatterycable. for the soundof it at the fuel fillerinlet.
5. Installthefuelfillercap.
6. lf no soundwas heard,measurethe voltage
betweenthe fuel pumpconnectorwire (Gff) to
chassisground.
Voltage:About12V
7. lf the voltageis normal,replacethe tuel pump.
8. lf you do not measure12V,repairthe relatedwire.
9. Disconnect thejumperwire.
22.10 FUELSYSTEM

,,r
I FuelPumpAssembly
2 FuelPumpAssembly
l
ElectricalConneclor

xar63-22QS tca r6322-0+s

HoldPressure
Do this inspectionif the pumpoperationinspectionis 6. Turn the ignitionswitchon for 10 secondslo runthe
notas soecified. luel pump.
1. Disconnectthe negativebatteryterminal. 7. Tum the ignitionswitcholf and removethejumper
wtre.
2. Releasefuel systempressure.Referto "Releasing
FuelSystemPressure"in this section. 8. Observethe fuelpressureafter5 minutes.
3. Connecta fuel pressuregaugeto the fuel filterand Fuel pressure:Morethan 50 psi (340kPa)
plugthe outletof the gaugeas shown.(lnstall 9. lf not as noted,replacethe fuel pump.
clampsas shown.)
Fuel PumpMaximumPressure
1. Disconneclthe negativebatteryterminal.
2. Releasefuel systempressure.Referto "Releasing
Fuel SystemPressure"in this section.
3. Connecta fuel pressuregaugeto the fuelfilterand
plug the oulletof the gaugeas shown.(lnstall
clampsas shown.)
4. Connectthe negativebatteryterminal.
5. Connectthe datalink connectorterminalsFUEL
PUMPand B+ witha jumperwire.
6. Tum the ignilionswitchon io run thetuelpump.
7. Measurethe fuel pumpmaximumpressure.
Fuel pump maximumpressure:above50 psi
(340 kPa)
8. Turn the ignitionswitchoff and removetheiumper
wtre.
9. lf this pressureis not measured.reDlace
thefuel
pump.
4. Connectthe negativebatery lerminal.
A WARNING
THEFUELSYSTEMREMA]NSUNDER FUELPUMPRELAYINSPECTION
PRESSURE WHENTHEENGINEIS NOT
RUNNING. RELEASEFUELSYSTEMPRESSURE CheckOperation
BEFOREDISCONNECTING ANY FUELLINETO A wlRtttttC
REDUCETHECHANCEOF PERSONAL INJURY THE FUELSYSTEMREMAINSUNDER
OR FIREDAMAGETO VEHICLECOMPONENTS. PRESSURE WHENTHEENGINEIS NOT
Connectthe datalinkconnectorterminalsFUEL BUNNING. RELEASE
FUELSYSTEMPRESSURE
PUMPand B+ witha jumper
wire. EEFORE DISCONNECTING
ANY FUELLINETO
REDUCETHECHANCEOF PERSONAL INJURY
OR FIREDAMAGETO VEHICLECOMPONENTS.
FUEL SYSTEM 22-11

Listenfor the fuel pumprelayclickingas the ignition


switchis turnedON. A WARNING
THEFUELSYSTEMREMAINSUNDER
ContinuityInspection PRESSURE WHENTHEENGINEIS NOT
RUNNING. RELEASEFUELSYSTEMPRESSURE
Checkcontinuitybetweenrelaylerminals. BEFOREDISCONNECTING ANY FUELLINETO
B+: Battery positive voltage REDUCETHECHANCEOF PERSONAL INJURY
OR FIREDAMAGETO THEVEHICLE.
Terminal2-4 Terminal$(1 or 3)
Releasetuel systempressure.Referto "Releasing
ApplyB+ Yes FuelSystemPressure"in this section.
B+ not applied No Connecta fuel pressuregaugeto the pressureport
locatedon the frontof the fuel rail.
Connectthe negativebatterylerminal.

KArSllt{r€

Connectthe datalinkconnectorterminalsFUEL
PRESSURE REGULATOR PUMPand B+ witha jumperwire.
INSPECTION Tumthe ignitionswitchon tor 10 seconds to run
thefuelpump.
FuelLine Pressure 7. Tumthe ignitionswitchoff and removethe jumper
1. Disconnectthe negativebatteryterminal. wire.
2. Releasefuelsystempressure.Referto "Releasing Pinchthe fuel returnhoseat the regulatorwith
FuelSystemPressure"in thissection. pliers.
3. Connecta luel pressuregaugeto the pressureport Observethe fuel oressurefor 5 minutes.
locatedon the frontof the fuel rail.
Fuel pressure:Morethan 21 psi (147kPa)
4. Connectthe negativebatteryterminal.
10. lf not as noted,replacethe pressureregulator.
5. Startthe engineand run it at idle. Referto the pressureregulatorreplacement sleps
6. Inspectthe fuel line pressuremeasurement. locatedin this manual.
Fuel line prcssure: 34 psi (235kPa)
7. Disconnectthe vacuumhoselromthe Dressure
regulatorand measurethe fuellinepressure.
Fuel line pressure:42 psi (292.5kPa)
Hold Pressure
Do this inspectionif the fuel line pressureinspectionis
not as noted.
1. Disconnect the negativebatteryterminal.

xtar6g-22{+s
22-12 FUELSYSTEM

FUELINJECTORINSPECTION
CheckOperation
1. Warmup the engineandlet it idle.
2. Listenfor the soundof eachiniectorrunningby
usinga soundscopeor a screwdriver.
A mnHrnc
FUELIS EXPLOSIVE.
WHENWORKINGON
FUELSYSTEMPARTS,MAKESURETO SUPPLY
ADEOUATEVENTILATION
TO THEWORK
AREA.DO NOTSMOKE.ANDKEEPSPARKS
AND OPENFLAMESAWAY.

KAtS$22-tqs
,

Connectthe datalinkconnectorterminalsFUEL
PUMPand B+ witha jumperwire.
4. Tum the ignition switchon.
5 . l'ilt the injectorsabout60 degreesandverifythat
no fuel leakstromthe iniectornozzles.
o . lf fuel leaks,replacethe leakinginjector.
Referto
"On-Vehicle Service"in this section.
7. Turnthe ignitionswitch"OFF and removethe
jumperwrre.

xtat 63-224\5

't
Caution
Make surc the fuel injectorc are firmly seated on
the tuel rail to prevent movementancl possible
damage,
3. lf no soundis heard,measureinjectorresisiance.
4. lf the iniecloris OK, checkwiringto the inieciorand
the voltagesof the ECMterminals16, 17, 34 and {tai 6i}22.tx\s
35.
5. lf removalof the iniectorsystemis needed,referto
"On-Vehicle Service"in this sectionfor the sieos.
FuelLeakageTest VolumeTest
'I. Takeout the iniectorstogether
withthe fuel rail. 1. Takeout the injectorstogetherwiththe fuelrail.
2. Securethe iniectorsto the tuel railwithwire. 2. Securethe injectorslo the distributorpipewith
wrre.
3. Connectan injectortesterto the batteryandthe
iniector.
4. Inspectthe injectorvolumewith a graduated
container.
Iniectorvolume:130cm' (130cc, 7.95)/min
FUELSYSTEM22.13
5. lf not as noted,replacethe injectors.Referlo 'On-
VehicleService'in this section. ON-VEHICLE
SERVICE
* Notice FUELTANK
. Always use new injectorO-ringswhen replacing Removal
injectors.
. Apply a small amountof cleanengine oil to each
A unnrrue
FUELIS EXPLOSIVE. AN EMPTYFUELTANK
of the O+ings beforeinstalling. CAN STILLCONTAINEXPLOSIVE GASES.
SUPPLYADEQUATEVENTILATION TO THE
WORKABEA.DO NOTSMOKEANDKEEP
SPARKSANDOPENFLAMESAWAY.PURGE
FUMESFROMTHETANKAS SOONAS
POSSIBLE.
1. Disconnectthe negativeterminalfromthebaftery.
2. Ooenthe rearaccessdoor of the vehicle.
3. Releasethe catchfor the rearseatandtilt it out of
lhe way.
4. Pull backthe souareof carDetin the areabehind
the tiltedseatwhichcoversthe fuelpumpassembly
accesspanelon the vehicletloor.
5. Disconnectthe two halvesof the fueloumo
assemblvelectricalconnector.

|(|Ar6+A-rl.s
,,r//
InjectorResistance
1. Disconnectthe iniectorharness.
2. Measureresistanceof the injector.
Resistance:12 -16f) @ 68'F (20'C)
3. lf not noted,replacethe injector.Referto "on-
VehicleService"in this seclionfor steos.

1 FuelPumpAssembly
2 FuelPumpAssembly
EleclricalConnector
xtal63,z-.t3€

6. Removethescrewholdingthe groundwirelugto
grouno.
7. Removethe four screwsattachingthe accesscover
and removethe accesscover,movingit out of the
way.
8. Removetwo fuel hoseclampsfromthe two fuel
hoseassemblies connectedto the fuelpump
assembly.
9. Disconnectthe twoluel hoseassemblies tromthe
fuelpumpassembly.
10. Disconnectfueltankpressuresensorelectrical
Ktar 6922-t2€ conneclor.
11. Workingthroughthe accessport,removethe three
fuel hoseclampsfromwherethethree{uel hoses
are connectedto the fuel iank.
22-14 FUELSYSTEM

Installation
A wlnNrlc
FUEL15 EXPLOSIVE. AN EMPTYFUELTANK
CAN STILLCONTAINEXPLOSIVEGASES.
SUPPLYADEQUATEVENTILATION TO THE
WORKAREA.OO NOTSMOKEAND KEEP
SPARKSAND OPENFLAMESAWAY.PURGE
FUMESFROMTHETANKAS SOONAS
POSSIBLE.
t . Raisethe vehicleon a hydrauliclift to the normal
undercarriage servicinglevel.
2. Attachthe shieldto the iuel tank usinotwo
attachingbolts.
Ensureany protectivecapsare removedfromthe
fuel tank oorts.
4. Placethe fueltank on a liftingdeviceeodcarefully
xtat 61t-22.ta-s
raisethe fueltank assemblyunderthe raised
12. Disconnectthe threefuel hosesfromthe nozzles vehicleuntilthe assemblyis positionedat the point
on the fueltank. ot installation.
13. Loosenthe inlethoseassembly jointclamp. Installtive l5 mm boltsto fastenthe fuel
14. Raisethe vehicleon a hydrauliclift to the normal tanldshieldassemblyinto placeon the vehicle
undercarriage chassis.
servicinglevel.
15. Usinga liftingdevice,raisethe liftingdeviceto the
bottomof the fueltank in the vehicle.Centerthe
liftingdeviceon the fueltanldshieldassembly.
16. Removelive 15 mm boltsfrom the fueltanldshield
assembly.
17. Carefullypullthe fueltanldshieldassemblvawav
fromthe chassisof the vehicleand allowihe
assemblyto reston the liftingdevice.
18. Lowerthe liftingdeviceand placethe fueltanU
shieldassemblyon a work bencharea.
't
Caution
Cover the open ports on the fuel tenk with
plastic caps or otlEr aveilable covers to avoid
luel vapor contaminating the work area.
19. Separatethe fueltankfromthe shieldby removing 1 FuelTank
two attachingbolts.Liftthe luel tank awayfromthe 2 Shield
shieldand storetheshield.

o. Lowerthe vehicleto groundleve..


7. Installthe inlethoseassemblyjoint clamp.
8. Connectthreefuel hosesto the nozzleson the fuel
tank.
9. Throughthe accessport,connectthreefuelhose
clampsto wherethe threefuel hosesare
connectedto the fuel tank.
1 0 .Connecttwo hosesto the fuel pumpassembly.
1 1 .Installtwo tuelhoseclampsto the pointwherethe
fuel hosesare connectedto the inletportson the
fueltank.
Pushthe endsot the mainfuel hose,luel return
hoseand evaporativehoseontothe fueltankfittino
at least1.0inch(25mm).Pushthefuetfi er hosej
ontothe tueltankpipesand fillerpipesat least
Klal692.l7.S
1.4inch(35mm).
FUELSYSTEM 22.15

1 FuelPumpAssembly
FuelPumpAssembly
ElectricalConnector
xar ql-zt. r0€

12. Connectfuel tank pressuresensorelectrical FUEL PUMPASSEMBLY


connector.
Removal
13. Insertthegrounding lineandthetuelpump
assemblyelectricalconnectorwiringthroughthe A wenlrHc
accessholein the accesspanel. FUELIS EXPLOSIVE. WHENWORKING ON
FUELSYSTEMPARTS,MAKE SURETO SUPPLY
14. Attachthe four screwsto attachtheaccesscoverto ADEOUATEVENTILANONTO THEWORK
the top of the accessareaoverthefuel pump AREA. DO NOTSMOKEAND KEEPSPARKS
assemblymountedin the fueltank. AND OPENFLAMESAWAY.
15. Attachthe groundwire lug to chassisgroundusing 1. Disconnecithe negativeterminalfromthe battery
the attachinoscrew.
Openthe rearaccessdoorof the vehicle.
Releasethe catchfor the backseatandtilt it out of
the way.
Pullbackthe squareof carpetin theareabehind
the tiltedseatwhichcoversthe tuel pumpassembly
accessoanelon vehiclefloor.
5. Disconnectthe two halvesof the fuelpump
assemblyelectricalconnector.
o. Removethe screwholdingthe groundwire lugto
grouno.
7. Removethe fourscrewsattachingthe.accesscover
and removethe accesscover,movingit out of the
way.
8. Removethe two tuel hoseclampsfromthe two fuel
hoseassembliesconnectedto fuel pumpassembly.

16. Connectthe two halvesof the fuelpumpassembly


electricalconnector.
17. Positionthe wiringinto placeusingan adhesive
stripand placethe squareof carpetingbackover
tFe accessareaon the vehicleflooring.
't8. Releasethe
catchfor lhe rearseatand bring it back
to the normalposition.
19. Closethe rearaccessdoorof thevehicle. - . - . \
20. Connectthe negativeterminalto the battery.
Klat 6922-1rtrs
22-16 FUELSYSTEM

* Notice
Do not use any excessiveforce on the fuel pump
assembly.Thepafts are delicate, suchas the fuel (:
screen which might be damagedby incorrect
rcmoval from the fuel tank.
9. Disconnectthe two fuel hosesfromthe fueloumo
assembly.
10. Bemoveeightretainingscrewsaroundthe top
surfaceof the fuel pumpassembly.
11. Whiletwistingverycarefully andtiltingthefuel
pumpassembly, pullgradually
untilit comesoutof
the top of the tueltank assembly.
'12.Whenthe fuelpump
assemblyis completelytaken
out of the accessarea,wrapit in a shoptowel
carefullyuntil it reachesthe maintenance area.
13. Sealofi the oDenJueltank Dortwitha coveror Kta163-22-22€
plug.
Holdingthefuelpumpassembly, guideit intothe
accessporton the top o{ the iuel tankas far as it
will go at that point.
Whiletwistingverycarefully,and tiltingthe luel
pumpassembly, pushgraduallyuntiltheassembly
seatsin the fueltankcorrectly.
Installeightretainingscrewsaroundthe top of the
installedfuel pumpassembly.

BNr422003

lnstallation
A unrurnc
FUELIS EXPLOSIVE. WHENWORKING ON K4163-22-?!15
FUELSYSTEMPARTS,MAKE SURETO
SUPPLYADEOUATEVENTILATION TO THE Connectthe two fuel hosesto the fueloumo
WORKAFEA,DO NOTSMOKEANDKEEP assembly.
SPARKSAND OPENFLAMESAWAY. 6 . Installthe two fuel hoseclampsto the twotuel
* Notice assembliesconnectedto the fuel pumpassembly.
Do not force fuel/ pump assemblyparts. The fuel/ 7. Inserithegroundwirein the fuelpumpassembly
screen is delicateand can be damagedby connectorassemblythroughthe accessholein the
improperinstallationto the fuel tank accesscover.
1. Removeany cap or protectivecoverirom the port 8. lnstallthe tour retainingscrewsattachingthe
on the loo of the fuel tank. accesscoverto the flooringof the vehicle.
9 . Attachthe groundwire lug to the flooringof the
vehiclewiththe atlachingscrew.
1 0 .Connectthe hvohalvesof the fuel pumpassembly
electricalconnector.
FUELSYSTEM22-17

1 FuelPumpAssembly
2 FuelPumpAssembly
Eleclrical
Conneclor x|Are22-rls
KtAl6+22-t+S

11. Placethe adhesivetape overthe loosewiringand Removethe two fuel hoseclampsfromthe twotuel
putthe squareof carpetingbackoverthe areaof hoseassembliesconnectedto the tuelpump
the accessdoorbehindthe rearseat. assembly.
12. Releasethe catchlor the rearseatand tilt it back Notice
intothe normalposition. Do not force fuel pump assemblypafts. The fuel
screenis delicateand can be damagedby
13. Closethe rearaccessdoorof the vehicle. improperremoval from the fuel tank.
14. Connectthe negativeterminalto the battery. a Disconnect the two fuel hosesfromthe fuel oumo
assembly.
1 0 .Disconnect fuel tank pressuresensorelectrical
connector.
FUELPUMPASSEMBLY
FILTEB 1.1. Removeeightretainingscrewsaroundthe top
surfaceot the fuel pumpassembly.
Removal 12. Whiletwistingvery carefullyand tiltingthe tuel
A wlnNrt'to pumpassembly,pullgraduallyon the assembly
FUELIS EXPLOSIVE. WHENWORKING ON untilit comesout of the too of the fueltank.
FUELSYSTEMPARTS,MAKESURETO
SUPPLYADEOUATEVENTILATION TO THE
WORKAREA.DO NOTSMOKEANDKEEP
SPARKSAND OPENFLAMESAWAY.
1. Disconnect the negativeterminaltromthe battery.
2. Openthe rearaccessdoorof the vehicle.
3. Releasethe catchfor the backseatand tilt it out of
the way.
4. Pullbackthe squareol carpetin the areabehind
the tiltedseatwhichcoversthe fuel pumpassembly
accessoanelon the vehiclefloor.
5. Disconnect the two halvesof the fuelpump
assemblyelectricalconnector.
6. Removethe screwholdingthe groundwire lug to
ground.
\
7. Removethe four screwsattachingthe accesscover
aNra220qt
and removethe accesscover,movingit out ol the
wav.

'I3. Whenthe tuel pump


assemblyis completely
taken
out of the accessarea,wrapit in a shoptowel
carefullyuntilit reachesthe maintenancearea.
22-18 FUELSYSTEM

xtarc+22.a2s

Installthe circularretainingclip at the endof the


BaI?A2264
fuel pumpto holdthe fuel filter (screen)to thefuel
pumpassembly. Thefuel pumpassemblyis now
't4. Sealoff the openfuel tank portwith readyto install.
a coveror
ptug. Holdingthe fuelpumpassembly,guideit intothe
tc. Removethe circularretaining clipat the end of the accessporton the top of the fuel tank as far as it
fuelpumpto allowthe fuel filter(screen)to will go at that point.
separatefrom the fuel pumpassembly.

\S-.....-o

I Fuel pump
2 Clip \
3 Screen
4 Pressure sensor for
leakage check of <) ..- 2 xat6+zt-r+s
vapor Ine
5 Nut * Notice
6 Dust Protection
tube lor sensor Do not force fuelpump assembly parts.Thefuel
aN7A22m5
screen is delicateand can be damagedby
improper rcmovaltrom the tank.
Whiletwistingverycarefully,and tiltingthefuel
pump assembly, pushgraduallyuntilthe assembly
lnstallation seats in the fueltankcorrectly.
A wlRntttc
FUELIS EXPLOSIVE. WHENWORKINGON
FUELSYSTEMPARTS,MAKESURETO
SUPPLYADEOUATEVENTILATION TO THE
WORKAREA.DO NOTSMOKEANDKEEP
SPARKSAND OPENFLAMESAWAY.
1. Removeany cap or protectivecoverfromthe port
on the too of the fuel tank.

x|Atdlzt-2ars
FUELSYSTEM 22.19

5. Installeightretainingscrewsaroundthe top sudace Pullbackthe squareof carpetin the areabehind


of the fuel pumpassembly. the tiltedseatwhichcoversihe fuelpumpassembly
6. Connectthe two fuel hosesto the fuel Dump accesspanelon the vehiclefloor.
assemory. Disconnect ihe two halvesof the fuelpump
7. Installthe two fuel hoseclamosto the two fuel assemblyelectricalconnector.
hosesconnectedto lhe fuel pumpassembly. 6 . Removethe screwholdingthe groundwire lug to
8. Connecttueltank Dressuresensorelectrical grouno.
conneclor. 7 . Removethe four screwsattaching
the accesscover
9. Insertthegroundwirein the fuelpumpassembly and removethe accesscover,movingit oui of the
connectorassemblythroughthe accessholein the
accesscover.
10. Installthe four retainingscrewsattachingthe
accesscoverto the tlooringof the vehicle.
1l. Attachthe groundwirelugto the flooringot the
vehiclewiththeattaching screw.
12. Connectthetwohalvesof the fuelpumpassembly
electricalconnector.
'13.Placethe
adhesivetapeoverthe loosewiringand
put the squareof carpetingbackoverthe areaof
the accessdoorbehindthe rearseat.
14. Releasethe catchfor the rearseatand tilt it out of
the way.
15. Closethe rearaccessdoorof thevehicle.
Kr 15+22-ra€
16. Connectthe negativeterminalto the battery.
8. Removethe two fuel hoseclamoslromthe two fuel
hosesconnectedto the fuel pumpassembly.
9. Disconnect the hvo fuel hosesfromthe fuel oumo
assembly.
* Notice
Do not use any excessiveforce on the fuel pump
assembly.Thepads are delicate,such as the fuel
screen whichmight be damagedby incorrect
removalfrom the fuel tank.
10. Removeeightretainingscrewsaroundthe top
surfaceof the fuel pumpassembly.
11. Disconnect fueltankoressure sensoreleclrical
connector.
1 FuelPumpAssembly 12. Whiletwistingvery carefullyandtiltingthe tuel
1 pumpassembly, pullgradually
2 FuelPumpAssembly on thefuelpump
Electrical
Connector assemblyuntilit comesout of the top of the fuel
xlar 6+2r-13s
lankassembly

FUELPUMP
Removal
A unHrHc
FUELIS EXPLOSIVE. WHENWORKING ON
FUELSYSTEMPARTS.MAKESURETO
SUPPLYADEQUATEVENTILATION TO THE
WORKAREA.DO NOTSMOKEANDKEEP
SPARKSAND OPENFLAMESAWAY.
1. Disconnectthe negativeterminaltromthe battery.
2. Openthe rearaccessdoorof the vehicle.
3. Releasethe catchfor the backseatand tilt it out of \
the way.
BN7A22i 03
22-20 FUELSYSTEM

13. Whenthe tuel pumpassemblyis completelytaken


out of the accessarea,wrapit in a shoptowel
carefullyuntilit reachesthe maintenancearea. /-:
14. Sealotf the openfuel tank portwitha coveror
ptug.
15. Removefour retainingscrewswhichholdthe fuel
pumpplasticretainingbracketto the fuel pump
assemblyframe.
16. Takeoff the retainingclampfromthe fuel hoseand
disconnectthe fuel hosefromthe fuel pump.
17. Takeofl the fuel pumpretainingplasticmounting
bracketas necessary.
18. Removefueltank pressuresensor

BN7A22(p3
I
Holdingthe fuelpumpassembty,guideit intothe
accessport on the top of the fuel tank as far as it
will go at that point.

1
2

ama2zr06

Installation
\
A wanHrl'tc BN7A2200g

FUELIS EXPLOSIVE. WHENWORKING ON


FUELSYSTEMPARTS,MAKESURETO t< Notice
SUPPLYADEOUATEVENTILATION TO THE Do not force fuelpump assemblypafts. Thefuet
WORKAREA.DO NOTSMOKEANDKEEP screen is delicateand can be damagedby
SPARKSAND OPENFLAMESAWAY. improperinstallationto the fuel tanK
1. Installthe plasticfuel pumpmountingbracketonto Whiletwistingverycarefullyand tiltingthe fuel
the fuel pumpand installthe four mountinoscrews pumpassembly,pushgraduallyon the assemblv
whichholdthe fuel pumpto the assembly-trame. untilit is in positionin the fuel tank assemblv.
2. Conneclthe fuel hoseto the fuel pumpand install
the retainingclampto securethe hoseto the fuel
pump.
3. Removeany cap or protectivecoverfromthe oort
on the top of the fuel tank.

KAi 6322-2aS
FUELSYSTEM 22-21
6. Installeightscrewsaroundthe top surfaceof the 1. Disconnect the negativeterminalfromthe battery.
fuel pumpassembly.
2. Openthe rearaccessdoorof the vehicle.
7. Connectthe two fuel hosesto the luel pump
assembly. 3. Releasethe catchtor the backseatandtilt it out of
the way.
8. Installthe two fuel hoseclampsto the two fuel
hosesconnectedto the fuel pumpassembly. 4. Pull backthe squareof carpeiin theareabehind
the tiltedseatwhichcoversthe fuelpumpassembly
9. Installfueltank oressuresensor. accessoanelon the vehiclefloor.
10. Connectfueltank pressuresensorelectrical 5. Disconnect the two halvesof the fuelpump
connector. assemblyelectricalconnector.
1l. Insertthe groundwireandthefuelpumpelectrical 6. Removethe screwholdingthe groundwire lug to
connectorwiresthroughthe accessholein the ground.
accessdoorand mountit overthe accesshole.
7. Removethe four screwsattachingtheaccesscover
12. Installfourscrewsto securethe accessdoorto the and removethe accesscover,movingit out of the
vehicleflooring. way.
13. Installthegroundwirelugto thefloorwiththe
attachingscrew.
'14.Connectthe two
halvesof the fuel pumpassembly
electricalconnector.
15. Attachadhesivetapeto any loosewiringand cover
the areaof the installedaccessdoorwiththe
squareof carpeting.
'16.Release
the catchfor the rearseatand out it to the
normaloosition.
'17.Closethe rear
accessdoorof lhe vehicle.
18. Connectthe negativeterminalto the battery

KAr e&22-lihs

8. Removethe two fuel hoseclampsfromthe two fuel


hosesconnectedto the tuel pumpassembly.
9. Disconnect the two fuel hosesfromthe fuel pump
assemoty.
* Notice
Do not force fuel pump assemblyparts-The fuel
screenis delicateand can be damagedby
improperremovalfrom the fuel tank.
1 FuelPurnpAssembly
10. Disconnect fueltank pressuresensorelectrical
FuelPumpAssembly connector.
Eleclrical
Connector 11. Removeeightretainingscrewsaroundthe top
surfaceof the fuel pumpassembly.
FUELTANKSENDER 12. Whiletwistingvery carefullyandtiltingthe fuel
pumpassembly, pullgradually
on thefuelpump
assemblyuntilit comesout of the topof the fuel
tankassemblv.
Removal

A wlnHrHc
FUELIS EXPLOSIVE.
WHENWORKING ON
FUELSYSTEMPARTS,MAKESURETO
SUPPLYADEOUATEVENTILATION
TO THE
WORKAREA.DO NOTSMOKE.AND KEEP
SPARKSAND OPENFLAMESAWAY.
22-22 FUELSYSTEM

\
aN7A2i!@

13. Whenthefuelpumpassemblyis completely taken


out of the accessarea,wrap it in a shoptowel
carefullyuntilit reachesthe maintenance area.
14. Sealoft the openfuel tank portwitha coveror
plug. Holdingthe assembledfuel pump/fuelsender
assembly,guideit intothe accessport on the top of
15. Removeretaininghardwarethat holdstheiuel tank thefueltankas far as it willgo.
senderassemblyto the fuel pumpassembly.

s--=l
sfu'-s
V'

1 FuelPumpAssembly
FuelTank \
SenderAssembly
3 FuelTankPressure
Sensor aNra22003
4N7A22007

* Notice
Do not force fuel pump assemblyparts. The fuel
Installation screenis delicate,and can be damagedby
A mRHlHc improperinstallationto the fuel tanK.
FUELIS EXPLOSIVE. WHENWOFKINGON Whiletwistingverycarefullyand tiltingthe fuel
FUELSYSTEMPARTS,MAKE SURETO pumpassembly, pushgradually on the assembly
SUPPLYADEOUATEVENTILATION TO THE untilit goes in positionin the fuel tank assembly.
WORKAREA.DO NOT SMOKEAND KEEP Installeightscrewsaroundthe top surfaceof the
SPARKSAND OPENFLAMESAWAY, fuel pumpassembly.
1. Installthe retaininghardwarethat holdsihe fuel Connectthe two fuel hosesassembliesto the fuel
senderassemblyto the fuel pumpassembly. pumpassembly.
2. Removeany capor protectivecoverfromthe port 7 . Installthe two tuel hoseclampsto the two fuel
on the toDol the fuel tank. hosesconnectedto the fuel pumpassembly.
Connectfuel tank pressuresensorelectrical
connector.

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